Composite panel, composite material, impregnator and method for manufacturing a composite panel

ABSTRACT

An impregnator for impregnating a fabric layer comprising: a chamber, the chamber being structured and arranged so as to retain a binding composition in a fluid state; a first opening being structured and arranged so as to allow the fabric layer entering the chamber in a dry state from a top portion of the chamber to be dived into the binding composition; and a second opening extending along the longitudinal axis of a bottom portion of the chamber, the second opening being structured and arranged to allow the fabric layer to exit from the bottom portion of the chamber in an impregnated state, the second opening comprising a first lip structured and arranged to be in contact with a first surface of the fabric layer and a second lip structured and arranged to be in contact with a second surface of the fabric layer.

CROSS-REFERENCE

The present application is a continuation of International PatentApplication No. PCT/IB2017/057624, filed on Dec. 4, 2017, entitled“COMPOSITE PANEL, COMPOSITE MATERIAL, IMPREGNATOR AND METHOD FORMANUFACTURING A COMPOSITE PANEL”, the entirety of which is incorporatedherein.

FIELD

The present technology relates to composite panels, composite material,impregnator and method for manufacturing composite panels. In someembodiments, but without being limitative, the composite panelsmanufactured in accordance with the present method may be used for themanufacturing of casings of air conditioning units.

BACKGROUND

Air conditioning units, in particular air conditioning units designedfor commercial and/or industrial applications are usually bundled intocasings. Such casings are typically made of panels designed so as towithstand certain constraints, in particular mechanical constraints andthermic constraints.

With respect to the mechanical constraints, the panels are designed soas to provide sufficient stiffness to allow displacement andinstallation of the air conditioning units, taking into considerationthat air conditioning units designed for commercial and/or industrialapplications may carry hundreds or even thousands kilograms of equipment(e.g., compressors, pumps, cooling assemblies, etc.).

With respect to the thermic constraints, the panels are designed so asto withstand important thermic variations without bonding and/orimpairing mechanical properties of the casing, in particular thermicvariations between an inside environment and an outside environment ofthe air conditioning unit, taking into consideration that suchvariations may reach up to 40 Celsius degrees in certain extremeenvironments.

Even though composite panels and/or composite materials have been widelyused in many industries, such as the aerospace and the automobileindustries, it is not yet the case in the air conditioning industry. Inparticular, air conditioning units designed for commercial and/orindustrial applications are still mainly made of metallic materials. Forexample, frames of the units and panels that are used for the outsidecasing and for dividing compartments within the air conditioning unitsare typically made of metallic materials such as aluminium and/ormetallic alloys.

Improvements may therefore be desirable, in particular improvementsrelating to composite panels, composite material and method ofmanufacturing composite panels that are, amongst other applications, tobe used for the manufacturing of casings of air conditioning units.

The subject matter discussed in the background section should not beassumed to be prior art merely as a result of its mention in thebackground section. Similarly, a problem mentioned in the backgroundsection or associated with the subject matter of the background sectionshould not be assumed to have been previously recognized in the priorart. The subject matter in the background section merely representsdifferent approaches.

SUMMARY

In one aspect, various implementations of the present technology providea composite panel comprising:

a first composite skin having a first fabric layer positioned between afirst Kraft paper layer and a second Kraft paper layer;

a second composite skin having a second fabric layer positioned betweena third Kraft paper layer and a fourth Kraft paper layer;

a foam core bonded to the first composite skin and to the secondcomposite skin; and

a binding composition applied to the first fabric layer and to thesecond fabric layer and penetrating the second Kraft paper layer and thethird Kraft paper layer so that the first composite skin is bonded to afirst surface of the foam core and the second composite skin is bondedto a second surface of the foam core, the binding composition being abio resin.

In some embodiments, the binding composition further penetrates thefirst Kraft paper layer and the fourth Kraft paper layer so as to form afirst hardened surface of the composite panel and a second hardenedsurface of the composite panel.

In some other embodiments, a composition of the bio resin comprisesPolyFurfuryl Alcohol (PFA).

In some embodiments, the first fabric layer and the second fabric layercomprise glass fibers, the glass fibers having a wet lay up thickness ofabout 2.4 millimeters.

In some embodiments, the composite panel withstand a temperature deltabetween a first environment contacting the first composite skin and asecond environment contacting the second composite skin of about 40Celsius degrees.

In some other embodiments, the foam core is made of PolyEthyleneTerephthalate (PET).

In some other embodiments, the first Kraft paper layer, the second Kraftpaper layer, the third Kraft paper layer and the fourth Kraft paperlayer have a weight of 127 g/m².

In some embodiments, the first composite skin and the second compositeskin are coplanar, the composite panel further comprising a thirdcomposite skin having a third fabric layer positioned between a fifthKraft paper layer and a sixth Kraft paper layer, the third compositeskin connecting to the first composite skin and to the second compositeskin by extending through the foam core, perpendicularly to the firstcomposite skin and the second composite skin.

In some embodiments, the casing of an air conditioning unit comprisesthe composite panel.

In yet another aspect, various implementations of the present technologyprovide a composite material comprising:

a first fabric layer positioned between a first Kraft paper layer and asecond Kraft paper layer, the first fabric layer comprising glassfibers, the glass fibers having a wet lay up thickness of about 2.4millimeters; and a binding composition applied to the first fabric layerand penetrating the first Kraft paper layer and the second Kraft paperlayer, the binding composition being a bio resin comprising PolyFurfurylAlcohol (PFA).

In another aspect, various implementations of the present technologyprovide a composite panel comprising:

a first skin having a first fabric layer positioned between a firstKraft paper layer and a second Kraft paper layer;

a foam core bonded to the first skin; and

a binding composition applied to the first fabric layer and penetratingthe second Kraft paper layer so that the first skin is bonded to a firstsurface of the foam core, the binding composition being a bio resin.

In yet another aspect, various implementations of the present technologyprovide a method for manufacturing a composite material, the methodcomprising:

positioning a first fabric layer between a first Kraft paper layer and asecond Kraft paper layer;

impregnating the first fabric layer with a binding composition whilemaintaining the first Kraft paper layer and the second Kraft paper layerdry;

assembling the impregnated first fabric layer, the first Kraft paperlayer and the second Kraft paper layer together to form a firstpre-impregnated multilayer assembly;

applying pressure on the first pre-impregnated multilayer assembly todiffuse the binding composition from the first fabric layer to the firstKraft paper layer and the second Kraft paper layer; and curing the firstpre-impregnated multilayer assembly.

In another aspect, impregnating the first fabric layer comprisestranslating the first fabric layer through an impregnator containing thebinding composition.

In yet another aspect, impregnating the first fabric layer is conductedwhile the first Kraft paper layer and the second Kraft paper layer arebypassing the impregnator.

In another aspect, the impregnated first fabric layer, the first Kraftpaper layer and the second Kraft paper layer are assembled downstreamthe impregnator.

In yet another aspect, the method further comprises prior to applyingpressure on the first pre-impregnated multilayer assembly:

laying the first pre-impregnated multilayer assembly on a first surfaceof a foam core;

cutting up the first pre-impregnated multilayer assembly;

forming a second pre-impregnated multilayer assembly from theimpregnated first fabric layer, the first Kraft paper layer and thesecond Kraft paper layer;

laying the second pre-impregnated multilayer assembly on a secondsurface of the foam core; and

cutting up the second pre-impregnated multilayer assembly.

In another aspect, applying pressure on the first pre-impregnatedmultilayer assembly further comprises applying pressure on the foam coreand the second pre-impregnated multilayer assembly so that the bindingcomposition penetrates the first Kraft paper layer and the second Kraftpaper layer of the first pre-impregnated multilayer assembly andpenetrates the first Kraft paper layer and the second Kraft paper layerof the second pre-impregnated multilayer assembly.

In yet another aspect, curing the first pre-impregnated multilayerassembly further comprises curing the foam core and the secondpre-impregnated multilayer assembly so as to form a composite panel.

In another aspect, positioning the first fabric layer between the firstKraft paper layer and the second Kraft paper layer further comprisespositioning a first veil layer between the first fabric layer and thefirst Kraft paper layer and positioning a second veil layer between thefirst fabric layer and the second Kraft paper layer.

In yet another aspect, positioning the first fabric layer between thefirst Kraft paper layer and the second Kraft paper layer comprisesunrolling a first roll comprising the first fabric layer, unrolling asecond roll comprising the first Kraft paper layer and unrolling a thirdroll comprising the second Kraft paper layer.

In yet another aspect, various implementations of the present technologyprovide impregnator for impregnating a fabric layer comprising:

a chamber extending along a longitudinal axis, the chamber beingstructured and arranged so as to retain a binding composition in a fluidstate;

a first opening extending along the longitudinal axis of a top portionof the chamber, the first opening being structured and arranged so as toallow the fabric layer entering the chamber in a dry state from the topportion of the chamber to be dived into the binding composition; and

a second opening extending along the longitudinal axis of a bottomportion of the chamber, the second opening being structured and arrangedto allow the fabric layer to exit from the bottom portion of the chamberin an impregnated state, the second opening comprising a first lipstructured and arranged to be in contact with a first surface of thefabric layer and a second lip structured and arranged to be in contactwith a second surface of the fabric layer.

In another aspect, the first lip and the second lip form a controlassembly allowing control of an impregnation rate of the bindingcomposition impregnating the fabric layer.

In yet another aspect, the first lip, the fabric layer and the secondlip form a sealing assembly allowing the fabric layer to translatethrough the second opening while preventing the binding composition toleak from the chamber.

In another aspect, the impregnator further comprises a first lateralseal positioned at a first lateral extremity of the chamber and a secondlateral seal positioned at a second lateral extremity of the chamber,the first lateral seal being structured and arranged so that a firstlateral band of the fabric layer remains dry while the fabric layertranslates through the chamber and the second lateral seal beingstructured and arranged so that a second lateral band of the fabriclayer remains dry while the fabric layer translates through the chamber.

In yet another aspect, the impregnator further comprises an inlet, asensor and a controller, the inlet allowing binding composition to beinjected into the chamber, the sensor allowing measurement of a level ofthe binding composition in the chamber and the controller comprisingcontrol logic allowing to control the inlet based on a reading generatedby the sensor.

In another aspect, the control logic further comprises instructionsallowing to maintain a level of the binding composition constant whilethe fabric layer translates through the chamber.

Amongst other benefits, the composite panels and the composite materialmay allow (1) to withstand a substantial variation (i.e., delta) betweena temperature inside an air conditioning unit and a temperature outsidethe air conditioning unit without bending and/or altering mechanicalproperties of the panel; (2) to carry a required mechanical load (e.g.,upon lifting off an air conditioning unit with a crane for installationon top of a building) while being lighter than conventional metallicmaterials; and/or (3) to present a certain level of fire protection(i.e., not easily flammable) so as to meet strengthened regulations.

Amongst other benefits, the impregnator used for the manufacturing ofcomposite material and the method for manufacturing composite panels mayallow (1) to produce panels within a cycle time suitable for high volumeproduction (e.g., less than 30 minutes per panel) and/or (2) limit therisk of having liquid resin to spill during the manufacturing therebyallowing to maintain a clean manufacturing environment.

In the context of the present specification, unless expressly providedotherwise, the words “first”, “second”, “third”, etc. have been used asadjectives only for the purpose of allowing for distinction between thenouns that they modify from one another, and not for the purpose ofdescribing any particular relationship between those nouns.

Implementations of the present technology each have at least one of theabove-mentioned object and/or aspects, but do not necessarily have allof them. It should be understood that some aspects of the presenttechnology that have resulted from attempting to attain theabove-mentioned object may not satisfy this object and/or may satisfyother objects not specifically recited herein.

Additional and/or alternative features, aspects and advantages ofimplementations of the present technology will become apparent from thefollowing description, the accompanying drawings and the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present technology, as well as otheraspects and further features thereof, reference is made to the followingdescription which is to be used in conjunction with the accompanyingdrawings, where:

FIG. 1 is a cross-sectional view of a composite panel in accordance withan embodiment of the present technology;

FIG. 2 is a perspective view taken from a top, front, left side of amanufacturing line in accordance with an embodiment of the presenttechnology;

FIG. 3 is a perspective view taken from a top, front, left side of a rowmaterial rack being a sub-portion of the manufacturing line of FIG. 2;

FIG. 4 is a perspective view taken from a top, front, left side of animpregnation module comprising an impregnator being a sub-portion of themanufacturing line of FIG. 2;

FIG. 5 is a cross-sectional view of an impregnator being a sub-portionof the impregnation module of FIG. 4;

FIG. 6 is a sectional view of the impregnator of FIG. 5 being takenalong the line A-A of FIG. 5;

FIG. 7 is a front view of a section of an impregnated fabric layer afterimpregnation through the impregnator of FIG. 6;

FIG. 8 is a front view taken from a top, front, left side of a firstcomposite panel and of a second composite panel in accordance with anembodiment of the present technology; and

FIG. 9 is a diagram illustrating a flowchart illustrating a method formanufacturing composite panels in accordance with an embodiment of thepresent technology.

It should also be noted that, unless otherwise explicitly specifiedherein, the drawings are not to scale.

DETAILED DESCRIPTION

The examples and conditional language recited herein are principallyintended to aid the reader in understanding the principles of thepresent technology and not to limit its scope to such specificallyrecited examples and conditions. It will be appreciated that thoseskilled in the art may devise various arrangements which, although notexplicitly described or shown herein, nonetheless embody the principlesof the present technology and are included within its spirit and scope.

Furthermore, as an aid to understanding, the following description maydescribe relatively simplified implementations of the presenttechnology. As persons skilled in the art would understand, variousimplementations of the present technology may be of a greatercomplexity.

In some cases, what are believed to be helpful examples of modificationsto the present technology may also be set forth. This is done merely asan aid to understanding, and, again, not to define the scope or setforth the bounds of the present technology. These modifications are notan exhaustive list, and a person skilled in the art may make othermodifications while nonetheless remaining within the scope of thepresent technology. Further, where no examples of modifications havebeen set forth, it should not be interpreted that no modifications arepossible and/or that what is described is the sole manner ofimplementing that element of the present technology.

Moreover, all statements herein reciting principles, aspects, andimplementations of the present technology, as well as specific examplesthereof, are intended to encompass both structural and functionalequivalents thereof, whether they are currently known or developed inthe future. With these fundamentals in place, we will now consider somenon-limiting examples to illustrate various implementations of aspectsof the present technology.

Referring to FIG. 1, there is shown a cross-section view of a compositepanel 10. The composite panel 10 comprises a first composite skin 60, afoam core 50 and a second composite skin 62. In the illustratedembodiment, the first composite skin 60 comprises a first fabric layer30 positioned between a first Kraft paper layer 20 and a second Kraftpaper layer 40. The second composite skin 62 comprises a second fabriclayer 32 positioned between a third Kraft paper layer 42 and a fourthKraft paper layer 22. In the illustrated embodiment, the composite panel10 is symmetrical about an axis 70.

A binding composition applied to the first fabric layer 30 and to thesecond fabric layer 32 penetrates the second Kraft paper layer 40 andthe third Kraft paper layer 42 so that the first composite skin 60 isbonded to a first surface of the foam core 50 and the second compositeskin 62 is bonded to a second surface of the foam core 50. In theillustrated embodiment, the binding composition further penetrates thefirst Kraft paper layer 20 and the fourth paper layer 22 so as to form afirst hardened surface of the composite panel 10 and a second hardenedsurface of the composite panel 10. In some embodiments, a first veillayer is positioned between the first fabric layer 30 and the firstKraft paper layer 20 and a second veil layer is positioned between thefirst fabric layer 30 and the second Kraft paper layer 40. In suchembodiments, the first veil layer and the second veil layer may increasea diffusing rate of the binding composition and improve uniformity ofhow the binding composition is spread across the surfaces of the variouslayers. Similarly, a third veil layer may be positioned between thesecond fabric layer 32 and the third Kraft paper layer 42 and a fourthveil layer may be positioned between the second fabric layer 32 and thefourth Kraft paper layer 22.

In some embodiments, the binding composition is a bio resin. The bioresin is a non-phenolic resin. In some embodiments, the bio resin doesnot comprise fire resistant filler material. In some embodiments, thebio resin is a non-phenolic resin which does not comprise fire resistantfiller material. As such, the bio resin is not a phenolic resin as maybe found in connection with the manufacturing of conventional fire-ratedlaminates. The bio resin is a resin that derives some or all of itsconstituent monomers from biological sources. In some embodiments, thebio resin comprises PolyFurfuryl Alcohol (PFA). In some embodiments, thebio resin is based on a PFA backbone. In some embodiments, the bio resinis free of Volatile Organic Compounds (VOC) as it is typically found inphenolic resins. As a result, the bio resin may reduce exposure topotential chemical hazards that may otherwise typically occur duringmanipulation of phenolic resin.

In some embodiments, the bio resin impregnates the first fabric layer 30and the second fabric layer 32. After pressure is applied on thecomposite panel 10 during manufacturing, the bio resin penetrates thefirst Kraft paper layer 20, the second Kraft paper layer 40, the thirdKraft paper layer 42 and the fourth Kraft paper layer 22. Once cured,the bio resin hardens thereby forming rigid surfaces formed by the firstKraft paper layer 20, the fourth Kraft paper layer 22. It should beunderstood that other type of bio resin may equally be used withoutdeparting from the scope of the present technology.

In some embodiments, the first fabric layer 30 and the second fabriclayer 32 are made from the same fabric material. In some embodiments,the fabric material comprises glass fibers. In some embodiments, thefabric material is selected so that the glass fibers have a wet lay upthickness of about 2.4 millimeters. In some embodiments, the wet lay upthickness ranges from 2.3 to 2.5 millimeters. In some embodiments, thewet lay up thickness ranges from 2.2 to 2.6 millimeters. In someembodiments, the wet lay up thickness ranges from 2.0 to 2.8millimeters. In some embodiments, the fabric material is E-Glass™. Itshould be understood that other type of fabric materials may equally beused without departing from the scope of the present technology.

In some embodiments, the first Kraft paper layer 20, the second Kraftpaper layer 40, the third Kraft paper layer 42 and the fourth Kraftpaper layer 22 are made from the same Kraft paper material. In someother embodiments, the first Kraft paper layer 20, the second Kraftpaper layer 40, the third Kraft paper layer 42 and the fourth Kraftpaper layer 22 are made from distinct Kraft paper materials. In someembodiments, the Kraft paper material has a packaging paper grade. Insome embodiments, the Kraft paper material has a weight of 127 g/m². Insome embodiments, the Kraft paper material has a weight which may rangefrom 122 g/m² to 137 g/m². In some embodiments, the Kraft paper materialis selected so as to allow proper penetration by the bio resin prior tocuring of the composite panel 10. It should be understood that varioustypes of Kraft paper material may be used without departing from thescope of the present technology.

In some embodiments, the foam core 50 is made from PolyEthyleneTerephthalate (PET). In other embodiments, the foam core 50 may be madeof different material than PET. The thickness and shape of the foam core50 may vary depending of the application. In the illustrated examples,the thickness of the foam core 50 may be selected so that the compositepanel 10 may be suitable for being part of a casing of an airconditioning unit. In the illustrated embodiment, the foam core 50, thefirst composite skin 60 and the second composite skin 62 are coplanarand symmetrical about the axis 70.

Amongst multiple applications, the specific construction of thecomposite panel 10 may make it suitable for being used in themanufacturing of casings of air conditioning units, in particular aspanels to be used for an outside of the casings and/or dividersinstalled within the casings of air conditioning units. The specificconstruction of the first composite skin 60, the foam core 50 and thesecond composite skin 62 may provide one or more of the followingbenefits, namely (1) withstanding a substantial variation (i.e., delta)between a temperature inside an air conditioning unit and a temperatureoutside the air conditioning unit without bending and/or alteringmechanical properties of the panel; (2) carrying a required mechanicalload (e.g., upon lifting off an air conditioning unit with a crane forinstallation on top of a building) while being lighter than conventionalmetallic materials; and/or (3) presenting a certain level of fireprotection (i.e., not easily flammable) so as to meet strengthenedregulations. In some embodiments, the specific combination of the fabriclayer, the Kraft paper layer and the bio resin as previously specifiedin the paragraph above allows meeting the norm ASTM E84 Cl. 1 with aflame index of 5 or less and a smoke index of 30 or less. With respectto withstanding a substantial variation (i.e., delta) between atemperature inside an air conditioning unit and a temperature outsidethe air conditioning unit, in some embodiments, the composite panel 10may withstand a temperature delta between a first environment contactingthe first composite skin and a second environment contacting the secondcomposite skin of about 40 Celsius degrees.

Other configurations of the composite panel 10 may also be envisioned,such as, but without being limitative, a composite panel comprising onlya first composite skin and a foam core. In some alternative embodiments,the second composite skin may be replaced by a different skin and/or adifferent material. As an example, an alternative embodiment ofcomposite panels may comprise a first composite skin having a firstfabric layer positioned between a first Kraft paper layer and a secondKraft paper layer; a foam core bonded to the first composite skin; and abinding composition applied to the first fabric layer and penetratingthe second Kraft paper layer so that the first composite skin is bondedto a first surface of the foam core, the binding composition being a bioresin.

In yet some alternative embodiments, the first composite skin may form acomposite material in itself which may be used for other applications(i.e., other than to be used in conjunction with a foam core and/or tobe part of a composite panel). As an example, such composite materialmay comprise a first fabric layer positioned between a first Kraft paperlayer and a second Kraft paper layer, the first fabric layer comprisingglass fibers, the glass fibers having a wet lay up thickness of about2.4 millimeters; and a binding composition applied to the first fabriclayer and penetrating the first Kraft paper layer and the second Kraftpaper layer, the binding composition being a bio resin comprisingPolyFurfuryl Alcohol (PFA.

Turning now to FIG. 2, an embodiment of a manufacturing line 100 isillustrated. In some embodiments, the manufacturing line 100 is used forthe manufacturing of composite panels such as the composite panel 10described in the previous paragraphs of the present document. In theembodiment illustrated at FIG. 2, the manufacturing line 100 comprises arow material rack 110, an impregnation module 140, a conveyor 170, acuring module 180 and a stocking module 190.

The row material rack 110 illustrated at FIG. 3 is adapted to receiveand maintain in place rolls of row materials to be used in connectionwith the manufacturing of the composite panel 10. In the illustratedembodiment, the rolls comprise a first roll of Kraft paper 120, a secondroll of Kraft paper 112, a third roll of fabric 116, a fourth roll ofveil 118 and a fifth roll of veil 114. In some embodiments, the firstroll of Kraft paper 120 may form what is referred to hereinafter as afirst Kraft paper layer 120. The second roll of Kraft paper 112 may formwhat is referred to hereinafter as a second Kraft paper layer 112. Thethird roll of fabric 116 may form what is referred to hereinafter as afirst fabric layer 116. The fourth roll of veil 118 may form what isreferred to hereinafter as a first veil layer and the fifth roll of veil114 may form what is referred to hereinafter as a second veil layer.

In some embodiments, a dimension of the rolls and a quantity of rowmaterial contained by each one of the rolls may be adapted for massproduction of composite panels, such as the composite panel 10.Therefore, the first roll of Kraft paper 120, the second roll of Kraftpaper 112, the third roll of fabric 116, the fourth roll of veil 118 andthe fifth roll of veil 114 may allow production of multiple compositepanels without a need to replace them each time a composite panel ismanufactured. In addition, the dimension of the rolls may vary dependingon the size of the composite panels to be manufactured.

As further illustrated in FIG. 4, the first roll of Kraft paper 120, thesecond roll of Kraft paper 112 and the third roll of fabric 116 fed theimpregnation module 140 via a top portion of the impregnation module140. The impregnation module 140 comprises an impregnator 140. In theillustrated embodiments, the impregnation module 140 is adapted for themanufacturing of composite skin and/or composite panels. The first Kraftpaper layer 120, the second Kraft paper layer 112 and the fabric layer116 are conveyed from the row material rack 110 within the impregnatormodule 140 by means of multiple mechanisms comprising actuatable rolls.The actuatable rolls may allow pulling the first Kraft paper layer 120,the second Kraft paper layer 112 and the fabric layer 116 within theimpregnation module 140. In the illustrated embodiment, the first Kraftpaper layer 120, the second Kraft paper layer 112 and the fabric layer116 are positioned so that the fabric layer 116 is positioned betweenthe first Kraft paper layer 120 and the second Kraft paper layer 112.The first Kraft paper layer 120, the second Kraft paper layer 112 andthe fabric layer 116 are also oriented so as to move along asubstantially vertical direction from the top of the impregnation module140 to the bottom of the impregnation module 140.

Turning now to FIG. 5, a cross-sectional view of the impregnator 142being attached to the impregnation module 140 via a frame 144 is shown.The impregnator 142 comprises a chamber 150, a first opening 148 and asecond opening 154.

The chamber 150 extends along a longitudinal axis and is structured andarranged so as to retain a binding composition in a fluid state. In someembodiments, the binding composition is a bio resin. In someembodiments, a viscosity of the binding composition may be controlled,for example, via a temperature control system associated with thechamber 150 (not shown). In the illustrated embodiment, a sensor 141 isinstalled within the chamber 150 so as to measure a level of the bindingcomposition within the chamber 150. In some embodiments, an inlet 143and a controller 145 may be associated with the chamber 150. The inlet143 may allow binding composition to be injected into the chamber 150and the controller 145 may comprise control logic allowing to controlthe inlet 143 based on a reading generated by the sensor 141. In someembodiments, the control logic comprises instructions allowing tomaintain a level of the binding composition constant while the fabriclayer 116 translates through the chamber 150 so as to be impregnatedwith the binding composition. In some embodiments, the control logicallows controlling an impregnation rate of the binding composition bythe fabric layer 116. In some embodiments, the controlling of theimpregnation rate may be achieved by controlling a level of the bindingcomposition in the chamber 150, a speed at which the fabric layer 116moves through the binding composition and/or a width of the secondopening 154.

The first opening 148 extends along a longitudinal axis of a top portionof the chamber 150. The first opening 148 may be dimensioned, structuredand arranged so that a fabric layer, such as the fabric layer 116, mayenter the chamber 150 in a dry state from the top portion of the chamber150 before being dived into the binding composition. The second opening154 extends along a longitudinal axis of a bottom portion of the chamber150. The second opening 154 may be dimensioned, structured and arrangedso that the fabric layer may exit the chamber 150 from the bottomportion of the chamber 150 in an impregnated state. As can be seen onFIG. 5, the second opening 154 comprises a first lip 146 structured andarranged so as to be in contact with a first surface of the fabric layer116 and a second lip 152 structured and arranged so as to be in contactwith a second surface of the fabric layer 116. The second opening 154formed by the first lip 146 and the second lip 152 may be dimensioned soas to be slightly wider than a thickness of the fabric later 116 so asto form a relatively sealed assembly avoiding the binding composition toleak through the second opening 154.

In some embodiments, the first lip 146 and the second lip 152 form acontrol assembly allowing control of an impregnation rate of the bindingcomposition impregnating the fabric layer. The first lip 146, the fabriclayer 116 and the second lip 152 form a sealing assembly allowing thefabric layer 116 to translate through the second opening whilepreventing the binding composition to leak from the chamber 150.

Turning now to FIG. 6, a sectional view of the impregnator 142 takenalong the line A-A of FIG. 5 is shown. The sectional view is taken fromthe top. The binding composition is located within the chamber 150. Afirst lateral seal 160 is positioned at a first lateral extremity of thechamber 150. A second lateral seal 164 is positioned at a second lateralextremity of the chamber 150. The first lateral seal 160 comprises afirst opening 162 allowing a first lateral band of the fabric layer 116to remain dry while the fabric layer 116 translates through the chamber150. The first opening 162 may be dimensioned so as to be slightly widerthan a thickness of the fabric later 116 so as to form a relativelysealed assembly avoiding the binding composition to leak through thefirst opening 162. Similarly, the second lateral seal 164 comprises asecond opening 166 allowing a second lateral band of the fabric layer116 to remain dry while the fabric layer 116 translates through thechamber 150. The second opening 166 may be dimensioned so as to beslightly wider than a thickness of the fabric later 116 so as to form arelatively sealed assembly avoiding the binding composition to leakthrough the second opening 166.

As an example, FIG. 7 illustrates a front elevational view of a segmentof the fabric layer 116 having exited the chamber 150. As can be seen,the fabric layer 116 comprises an impregnated area 170, a first lateralband 172 and a second lateral band 174. Only the impregnated area 170has been impregnated while the first lateral band 172 and the secondlateral band 174 having translated through the first opening 162 and thesecond opening 166 remain dry. Amongst multiple benefits, the firstlateral band 172 and the second lateral band 174 may act as a “bufferzone” when pressure is applied on the fabric layer 116 down themanufacturing line 100. Upon being subjected to pressure, at least aportion of the binding composition may be pushed towards the firstlateral band 172 and the second lateral band 174. The first lateral band172 and the second lateral band 174 may absorb the overflow of thebinding composition thereby limiting spilling of the binding compositionfrom the lateral sides of the fabric layer 116.

As a person skilled in the art of the present technology may appreciate,the impregnator 142 allows impregnating the fabric layer 116 while thefirst Kraft paper layer 120 and the second Kraft paper layer 112 remaindry. After the fabric layer 116 has been impregnated, the first Kraftpaper layer 120, the fabric layer 116 and the second Kraft paper layer112 may be reassembled at a position downstream the impregnator 142 toform a pre-impregnated multilayer assembly. The pre-impregnatedmultilayer assembly may be then subjected to a pressure selected so asto diffuse the binding composition from the fabric layer 116 to thefirst Kraft paper layer 120 and the second Kraft paper layer 112. Thepre-impregnated multilayer assembly may then be cured to form acomposite skin and/or a composite panel.

In some embodiments, after the fabric layer 116 has been impregnated andthe first Kraft paper layer 120, the fabric layer 116 and the secondKraft paper layer 112 have been reassembled to form the pre-impregnatedmultilayer assembly, the pre-impregnated multilayer assembly may be laidout on the conveyor 170 and cut up to form a first composite skin of agiven size. In some embodiments wherein a composite panel is to beproduced, a foam core, such as the foam core 50, may then be positionedon top of the first composite skin. A second composite skin may then beproduced from the first Kraft paper layer 120, the fabric layer 116 andthe second Kraft paper layer 112. The second composite skin may then belaid out on top of the foam core 50 and cut up. In some embodiments,powder coating may be applied on the first composite skin and/or thesecond composite skin. The composite panel comprising the firstcomposite skin, the foam core and the second composite skin may then beconveyed into the curing module 180. In some embodiments, the curingmodule 180 combines at least three functionalities, namely (1) a firstfunction allowing the curing module 180 to apply pressure on thecomposite panel so that the binding composition of the first compositeskin and the second composite skin diffuses from the fabric layers toKraft paper layers; (2) a second function allowing the curing module 180to cure the composite panel thereby allowing the binding composition tosolidify; and (3) a third function allowing the curing module 180 tocool the composite panel at a higher rate than if the composite panelwas cooled by ambient air thereby improving a solidification process ofthe binding composition and reducing a production cycle time. In someembodiments, the first function, the second function and/or the thirdfunction are applied sequentially.

Once the composite panel is cured and cooled, the composite panel may bemoved from the curing module 180 to a stocking module such as thestocking module 190 of FIG. 2.

Turning now to FIG. 8, an alternative embodiment of composite panels 102and 104 are shown. Similarly to the composite panel 10 of FIG. 1, thecomposite panels 102 and 104 comprise a first composite skin 60 and asecond composite skin 62. As for the composite panel 10, the firstcomposite skin 60 and the second composite skin 62 are coplanar. In boththe composite panels 102 and 104, a third composite skin 64 extendsperpendicularly from the first composite skin 60 to the second compositeskin 62. The third composite skin 64 may be made from a fabric layer, afirst Kraft paper layer and a second Kraft paper layer as it is the casefor the first composite skin 60 and the second composite skin 62. Thethird composite skin 64 may have a different thickness than the firstcomposite skin 60 and the second composite skin 62. The third compositeskin 64 extends through respective foam cores of the composite panels102 and 104. In some embodiments, multiple composite skins such as thethird composite skin 64 may be positioned across the foam cores of thecomposite panels 102 and 104. In some embodiments, such construction mayallow reinforcing a rigidity of the composite panels 102 and 104. Insome embodiments, the composite panel 102 may be used for themanufacturing of side panels of air conditioning cases and the compositepanel 104 may be used for the manufacturing of floor panels of airconditioning cases.

Turning now to FIG. 9, a flowchart illustrating a method formanufacturing composite panels, composite skins and/or compositematerial is disclosed. In some embodiments, the method 900 may be(completely or partially) implemented on the manufacturing line 100.

The method 900 may start at step 902 by positioning a first fabric layerbetween a first Kraft paper layer and a second Kraft paper layer. Insome embodiments, positioning the first fabric layer between the firstKraft paper layer and the second Kraft paper layer further comprisespositioning a first veil layer between the first fabric layer and thefirst Kraft paper layer and positioning a second veil layer between thefirst fabric layer and the second Kraft paper layer. In someembodiments, positioning the first fabric layer between the first Kraftpaper layer and the second Kraft paper layer comprises unrolling a firstroll comprising the first fabric layer, unrolling a second rollcomprising the first Kraft paper layer and unrolling a third rollcomprising the second Kraft paper layer.

Then, at a step 904, the method 900 proceeds to impregnating the firstfabric layer with a binding composition while maintaining the firstKraft paper layer and the second Kraft paper layer dry. In someembodiments, impregnating the first fabric layer comprises translatingthe first fabric layer through an impregnator containing the bindingcomposition. In some embodiments, impregnating the first fabric layer isconducted while the first Kraft paper layer and the second Kraft paperlayer are bypassing the impregnator.

At a step 906, the method 900 proceeds to assembling the impregnatedfirst fabric layer, the first Kraft paper layer and the second Kraftpaper layer together to form a first pre-impregnated multilayerassembly. In some embodiments, the impregnated first fabric layer, thefirst Kraft paper layer and the second Kraft paper layer are assembleddownstream the impregnator.

At a step 908, the method 900 proceeds to applying pressure on the firstpre-impregnated multilayer assembly to diffuse the binding compositionfrom the first fabric layer to the first Kraft paper layer and thesecond Kraft paper layer. At a step 910, the method 900 proceeds tocuring the first pre-impregnated multilayer assembly.

In some embodiments, the method 900 further comprises, prior to applyingpressure on the first pre-impregnated multilayer assembly:

laying the first pre-impregnated multilayer assembly on a first surfaceof a foam core;

cutting up the first pre-impregnated multilayer assembly;

forming a second pre-impregnated multilayer assembly from theimpregnated first fabric layer, the first Kraft paper layer and thesecond Kraft paper layer;

laying the second pre-impregnated multilayer assembly on a secondsurface of the foam core; and

cutting up the second pre-impregnated multilayer assembly.

In some embodiments, applying pressure on the first pre-impregnatedmultilayer assembly further comprises applying pressure on the foam coreand the second pre-impregnated multilayer assembly so that the bindingcomposition penetrates the first Kraft paper layer and the second Kraftpaper layer of the first pre-impregnated multilayer assembly andpenetrates the first Kraft paper layer and the second Kraft paper layerof the second pre-impregnated multilayer assembly.

In some embodiments, curing the first pre-impregnated multilayerassembly further comprises curing the foam core and the secondpre-impregnated multilayer assembly so as to form a composite panel.

While the above-described implementations have been described and shownwith reference to particular steps performed in a particular order, itwill be understood that these steps may be combined, sub-divided, orre-ordered without departing from the teachings of the presenttechnology. At least some of the steps may be executed in parallel or inseries. Accordingly, the order and grouping of the steps is not alimitation of the present technology.

It should be expressly understood that not all technical effectsmentioned herein need to be enjoyed in each and every embodiment of thepresent technology. For example, embodiments of the present technologymay be implemented without the user enjoying some of these technicaleffects, while other embodiments may be implemented with the userenjoying other technical effects or none at all.

Modifications and improvements to the above-described implementations ofthe present technology may become apparent to those skilled in the art.The foregoing description is intended to be exemplary rather thanlimiting. The scope of the present technology is therefore intended tobe limited solely by the scope of the appended claims.

What is claimed is:
 1. An impregnator for impregnating a fabric layercomprising: a chamber extending along a longitudinal axis, the chamberbeing structured and arranged so as to retain a binding composition in afluid state; a first opening extending along the longitudinal axis of atop portion of the chamber, the first opening being structured andarranged so as to allow the fabric layer entering the chamber in a drystate from the top portion of the chamber to be dived into the bindingcomposition; a second opening extending along the longitudinal axis of abottom portion of the chamber, the second opening being structured andarranged to allow the fabric layer to exit from the bottom portion ofthe chamber in an impregnated state, the second opening comprising afirst lip structured and arranged to be in contact with a first surfaceof the fabric layer and a second lip structured and arranged to be incontact with a second surface of the fabric layer; a first lateral sealpositioned at a first lateral extremity of the chamber, the firstlateral seal being structured and arranged so that a first lateral bandof the fabric layer remains dry while the fabric layer translatesthrough the chamber; a second lateral seal positioned at a secondlateral extremity of the chamber, the second lateral seal beingstructured and arranged so that a second lateral band of the fabriclayer remains dry while the fabric layer translates through the chamber;and wherein the first lateral band and the second lateral band define abuffer zone adapted to absorb an overflow of the binding compositionthereby limiting spilling of the binding composition from lateral sidesof the fabric layer when the fabric layer is subjected to pressure. 2.The impregnator of claim 1, wherein the first lip and the second lipform a control assembly allowing control of an impregnation rate of thebinding composition impregnating the fabric layer.
 3. The impregnator ofclaim 1, wherein the first lip, the fabric layer and the second lip forma sealing assembly allowing the fabric layer to translate through thesecond opening while preventing the binding composition to leak from thechamber.
 4. The impregnator of claim 3, further comprising an inlet, asensor and a controller, the inlet allowing binding composition to beinjected into the chamber, the sensor allowing measurement of a level ofthe binding composition in the chamber and the controller comprisingcontrol logic programmed to control the inlet based on a readinggenerated by the sensor.
 5. The impregnator of claim 4, wherein thecontrol logic further comprises instructions programmed to maintain alevel of the binding composition constant while the fabric layertranslates through the chamber.
 6. The impregnator of claim 1, whereinthe second opening has a width defined by a distance between the firstlip and the second lip, the width being wider than a thickness of thefabric layer so as to allow the fabric layer to exit the chamber in theimpregnated state while avoiding the binding composition to leak throughthe second opening.
 7. The impregnator of claim 4, wherein thecontroller is further programmed to control an impregnation rate of thebinding composition by the fabric layer based on a level of the bindingcomposition in the chamber, a speed at which the fabric layer movesthrough the binding composition and the width of the second opening. 8.The impregnator of claim 4, further comprising a temperature controlsystem adapted to control a temperature of the chamber thereby allowingcontrol of a viscosity of the binding composition.
 9. The impregnator ofclaim 1, wherein the first lip extends along a vertical axis from afirst lip bottom to a first lip top, the second lip extends along thevertical axis from a second lip bottom to a second lip top; the firstlip bottom and the second lip bottom being positioned below the bottomportion of the chamber and the first lip top and the second lip topbeing positioned above the bottom portion of the chamber.